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Maintenance & Inspection - Johnstech

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<strong>Maintenance</strong><br />

& <strong>Inspection</strong><br />

Guide<br />

Pad ROL 200 Series<br />

PRODUCTION TEST CONTACTORS<br />

Your Contact For Higher Performance


Pad ROL200<br />

Series<br />

About <strong>Johnstech</strong><br />

Since 1992, <strong>Johnstech</strong> International Corporation,<br />

headquartered in Minneapolis, MN, has<br />

been a leading provider of interconnect solutions<br />

for semiconductor manufacturers who<br />

want higher first-pass yields and lower overall<br />

cost of test. <strong>Johnstech</strong>’s high performance<br />

Test Contactors are available in Pad, Leaded<br />

and Edge packages and are based on patented<br />

technology that provides superior electrical<br />

and mechanical performance. <strong>Johnstech</strong> also<br />

partners with Handler, Tester and Load Board<br />

manufacturers to ensure appropriate interfaces.<br />

With offices in the United States and<br />

Singapore; Field Service offices in California,<br />

Singapore, Philippines; and representation in<br />

China, Israel, Japan, Korea, Southeast Asia<br />

(Malaysia, Philippines, Singapore, Thailand)<br />

and Taiwan, <strong>Johnstech</strong> is proud to provide<br />

worldwide service and support.<br />

(Please refer to the back cover for addresses<br />

and phone numbers or go to our website at<br />

www.johnstech.com.)<br />

www.johnstech.com<br />

©2010 <strong>Johnstech</strong> International Corporation<br />

All rights reserved.<br />

2


Table of Contents<br />

Standard Product Information . . . . . . . . . . . . . . . . . 4<br />

Contactor Component Information . . . . . . . . . . . . 5<br />

Contactor Identification Information ...........6<br />

Contactor Configuration Verification . . . . . . . . . . 7<br />

Recommended Tools. . . . . . . . . . . . . . . . . . . . . . . . . . 8<br />

Cleaning and <strong>Maintenance</strong> Frequency . . . . . . . . . 9<br />

Pre-<strong>Maintenance</strong> Troubleshooting. . . . . . . . .10-11<br />

Load Board & Contactor <strong>Inspection</strong> . . . . . . . . . . .12<br />

Load Board <strong>Inspection</strong> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12<br />

Contactor <strong>Inspection</strong>. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12<br />

Housing, Elastomer & Contact <strong>Inspection</strong> . . . . .13<br />

Housing <strong>Inspection</strong> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13<br />

Elastomer <strong>Inspection</strong>. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13<br />

Contact <strong>Inspection</strong> ................................... 13<br />

Oxide Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13<br />

Contactor Removal & Installation . . . . . . . . . . . . .14<br />

Contact & Elastomer Removal . . . . . . . . . . . . . . . .15<br />

Contactor Cleaning . . . . . . . . . . . . . . . . . . . . . . .16-18<br />

Light Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16<br />

Thorough/Ultrasonic Cleaning. . . . . . . . . . . . . . . . . . . . . . . . 18<br />

Elastomer Installation . . . . . . . . . . . . . . . . . . . . . . . .19<br />

Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . .20<br />

Installation Verification . . . . . . . . . . . . . . . . . . . . . . .21<br />

Grounding Information . . . . . . . . . . . . . . . . . . .22-25<br />

Grounding Solutions Information. . . . . . . . . . . . . . . . . . . . . 22<br />

Ground Insert Removal ............................... 23<br />

Ground Insert Installation (New RCI) . . . . . . . . . . . . . . . . . . 24<br />

Ground Insert Installation (Snap Fit RCI) ............... 25<br />

Pad ROL200<br />

Series<br />

For questions about anything contained in<br />

this <strong>Maintenance</strong> & <strong>Inspection</strong> Guide,<br />

contact your local <strong>Johnstech</strong> representative.<br />

If you are experiencing a technical problem<br />

or issue, fill out the online Tech Help Form at:<br />

www.johnstechhelp.com<br />

(All forms will be responded to within two business days.)<br />

OR contact the nearest Field Service Office.<br />

(Turn to the back cover for addresses/phone numbers.)<br />

3<br />

I<br />

www.johnstech.com<br />

©2010 <strong>Johnstech</strong> International Corporation<br />

All rights reserved.


Pad ROL200<br />

Series<br />

Gold-Plated Fine Tip Contact<br />

Matte Tin Configuration<br />

>0.5mm pitch<br />

(Contact # 138337-0001)<br />

Gold-Plated Fine Tip Contact<br />

Matte Tin Configuration<br />

0.4mm pitch<br />

(Contact # 138337-0002)<br />

Low-Force XL-2 Fine Tip Contact<br />

NiPdAu Configuration<br />

>0.5mm pitch<br />

(Contact # 160369-0001)<br />

Standard Product Information<br />

Electrical Specifications<br />

(Measured using Gold-Plated and Low-Force XL Contact<br />

Configurations, shown on left, for Matte Tin and NiPdAu packages.)<br />

Matte Tin NiPdAu<br />

Electrical Length: . . . . . . . . . . . . . 2.00 mm . . . . . . . . 2.07 mm<br />

Inductance — Self: . . . . . . . . . . . . . 0.42 nH . . . . . . . . 0.55 nH<br />

Mutual: . . . . . . . . . . . 0.24 nH . . . . . . . . . 0.24 nH<br />

Capacitance — Ground: . . . . . . . . . . 0.35 pF . . . . . . . . 0.35 pF<br />

Mutual: . . . . . . . . . . 0.13 pF . . . . . . . . . 0.12 pF<br />

S21 Insertion Loss (G-S-G): . . . . . . . . -1 dB@24 GHz . . . . -1 dB@18.5 GHz<br />

S11 Return Loss (G-S-G): . . . . . . . . . . -20 dB@4 GHz . . . -20 dB@5.8 GHz<br />

S41 Crosstalk (G-S-S-G): . . . . . . . . . . -20 dB@18 GHz . . -20 dB@29.5 GHz<br />

Average Contact DC Resistance: . . . . . 30 mΩ . . . . . . . . . . 20 mΩ<br />

Current Carrying Capability: . . . . . . . . 4 A . . . . . . . . . . . .2.8 A<br />

Current Leakage: . . . . . . . . . . . . . . . 0.50mm pitch 160369-0001 160995-0010 160995-0100<br />

Full Tip, 0.40mm pitch 161503-0001 161504-0010 161504-0100<br />

Spares Spares<br />

Elastomers Kit - 1 Kit - 5<br />

Inner/Front Elastomer (Gray) 138335-0001 138335-0005<br />

Outer/Back Elastomer (Yellow) 159628-0001 159628-0005<br />

Inner/Front Elastomer (Blue) 110232-0001 123127-0001<br />

Outer/Back Elastomer (Red) 119493-0001 119493-0005<br />

RCI Ground Insert Kit - 1 Kit - 5<br />

Blue retention Elastomer 152676-0001 152676-0005<br />

3X3 EI Insert - Kit of 10<br />

Green Retention Elastomer 145549-0010 Red Bias Elastomer 145548-0010<br />

4X4 EI Insert - Kit of 10<br />

Green Retention Elastomer 145551-0010 Red Bias Elastomer 145550-0010


Contactor Components<br />

Methodology (showing Gold-Plated Contact Configuration)<br />

Device Under Test<br />

Contact<br />

Inner/Front Elastomer<br />

Outer/Back Elastomer<br />

Pad ROL200<br />

Series<br />

Note: The Gray/Yellow<br />

elastomer and Gold-Plated<br />

Contact (138337) for<br />

matte tin packages are<br />

shown in the illustrations<br />

throughout this document.<br />

For the NiPdAu package<br />

configuration, refer to<br />

page 4 for the correct<br />

contact and elastomer<br />

configuration.<br />

Contactor Components<br />

Load Board<br />

Standard Parts<br />

Most <strong>Johnstech</strong> Contactors<br />

have four standard parts<br />

that comprise the Contactor<br />

assembly:<br />

· Housing<br />

· Contacts<br />

· Elastomers<br />

· Acrylic Mounting Plate<br />

· Alignment Plate*<br />

Double-Latch Vertically Compliant<br />

Manual Actuator (DL-VCMA)*<br />

A Manual Actuator is available<br />

for short-run testing<br />

and characterization and/or<br />

troubleshooting.<br />

Alignment Plate<br />

*A Single-Latch Vertically<br />

Compliant Manual Actuator<br />

(SL-VCMA) is also available<br />

for selected Housing sizes;<br />

pictured here:<br />

Housing<br />

Fully-Assembled Contactor<br />

Acrylic Mounting Plate<br />

5<br />

www.johnstech.com<br />

©2010 <strong>Johnstech</strong> International Corporation<br />

All rights reserved.


Pad ROL200<br />

Series<br />

Identification<br />

Each <strong>Johnstech</strong> Contactor<br />

will have as much information<br />

as space allows. The<br />

identification system is designed<br />

to provide you with<br />

the technical information<br />

you need to identify the<br />

Contactor and its Design<br />

Data Sheet (example shown<br />

on the facing page).<br />

Contactor Identification<br />

Sample Contactor, Load Board Side Up<br />

9. Device Body 1. Manufacturer 6. Assembly 7. Device 8. Device<br />

Size (mm) Type Count Type<br />

5. Design Number<br />

10. Pitch (mm)<br />

3. Manufacturing<br />

Date Code<br />

Here is how to read the<br />

different data fields on the<br />

Contactors:<br />

1. JTI- identifies <strong>Johnstech</strong><br />

International as<br />

the manufacturer<br />

2. Serial Number<br />

3. Manufacturing Date<br />

Code (see tables at right)<br />

4. Perimeter Contact Width<br />

(in inches)<br />

5. Design Number<br />

For Custom Orders:<br />

1234-YYZZ<br />

YY = Contactor Technology<br />

Code (i.e. 01 =<br />

ROL100; 02 =<br />

ROL200)<br />

ZZ = Configuration<br />

(or design iteration)<br />

Number<br />

For SelecTest Orders:<br />

6XXX-8XXXXX<br />

6XXX = Design Number<br />

8XXXXX = Configuration<br />

Number<br />

6. Assembly Type<br />

TS: Test Socket<br />

MA: Manual Actuator<br />

SL: Single-Latch MA<br />

DL: Double-Latch MA<br />

7. Device Perimeter Pad<br />

Count<br />

8. Device Type<br />

9. Device Body Size (mm)<br />

10. Device Pad Pitch (mm)<br />

11. Part Number (will appear<br />

only if Contactor is<br />

a SelecTest® order)<br />

Date Code Reference<br />

Week<br />

Week<br />

Letter Number Letter Number<br />

A 1 AA 27<br />

B 2 AB 28<br />

C 3 AC 29<br />

D 4 AD 30<br />

E 5 AE 31<br />

F 6 AF 32<br />

G 7 AG 33<br />

H 8 AH 34<br />

I 9 AI 35<br />

J 10 AJ 36<br />

K 11 AK 37<br />

L 12 AL 38<br />

M 13 AM 39<br />

N 14 AN 40<br />

O 15 AO 41<br />

P 16 AP 42<br />

Q 17 AQ 43<br />

R 18 AR 44<br />

S 19 AS 45<br />

T 20 AT 46<br />

U 21 AU 47<br />

V 22 AV 48<br />

W 23 AW 49<br />

X 24 AX 50<br />

Y 25 AY 51<br />

Z 26 AZ 52<br />

11. Part Number<br />

2. Serial Number<br />

4. Perimeter<br />

Contact Width<br />

Letter<br />

Year<br />

A 1991<br />

B 1992<br />

C 1993<br />

D 1994<br />

E 1995<br />

F 1996<br />

G 1997<br />

H 1998<br />

I 1999<br />

J 2000<br />

K 2001<br />

L 2002<br />

M 2003<br />

N 2004<br />

O 2005<br />

P 2006<br />

Q 2007<br />

R 2008<br />

S 2009<br />

T 2010<br />

U 2011<br />

V 2012<br />

www.johnstech.com<br />

©2010 <strong>Johnstech</strong> International Corporation<br />

All rights reserved.<br />

6<br />

Date Code Examples:<br />

SN123456BK B = Week 2 K = 2001<br />

SN654321AAN AA = Week 27 N = 2004


Contactor Configuration Verification<br />

Verify the Alignment Plate<br />

Alignment Plate Part Number<br />

only. Check this number against<br />

the Part Number on the Design<br />

Data Sheet to ensure it is the<br />

correct one.<br />

Example of Design Data Sheet<br />

Alignment Plate for same Housing,<br />

but with a different-sized<br />

opening; and that opening size<br />

information.<br />

Pad ROL200<br />

Series<br />

Design Data Sheet<br />

The Design Data Sheet contains<br />

Contactor Specifications<br />

on Load Board layout,<br />

Handler plunge depth, Alignment<br />

Plate opening size and<br />

other information necessary<br />

for setup and troubleshooting.<br />

Refer to it to verify you<br />

are using the correct:<br />

· Alignment Plate (for manual<br />

vs. automated testing<br />

and opening-to-body)<br />

· Contacts (refer to part<br />

number and thickness)<br />

· Elastomer Configuration<br />

· Load Board Layout<br />

Alignment Plate<br />

Verification<br />

Refer to the Design Data<br />

Sheet to ensure the proper<br />

Alignment Plate is being<br />

used. Different package<br />

vendors and Handlers<br />

require different Alignment<br />

Plates. The Design Data<br />

Sheet will specify which<br />

one is right for which application,<br />

as well as any<br />

special engraving to assist<br />

with identification.<br />

7<br />

www.johnstech.com<br />

©2010 <strong>Johnstech</strong> International Corporation<br />

All rights reserved.


Pad ROL200<br />

Series<br />

Recommended Tools<br />

Screwdriver with Allen-Head Bits— for fastening the Contactor<br />

to the Load Board<br />

10X Eye Loupe— for magnified inspection of Contactor,<br />

Elastomers and Contacts<br />

Elastomer Tool— for use in Elastomer Installation as well as<br />

prying Alignment Plate from Contactor<br />

Fine-Tip Non-Metallic Tweezers— for handling Contacts<br />

and Elastomers<br />

Scalpel— for marking Elastomer lengths<br />

Micro Scissors— for cutting Elastomers to length<br />

Probe Tool— for use in Elastomer Installation<br />

Recommended Tools<br />

(in order at right)<br />

CAUTION: Avoid touching<br />

the Device- and Load<br />

Board-interface surfaces<br />

of the Contacts with<br />

metal tools. Scratches<br />

on these areas may<br />

degrade performance.<br />

Fiberglass Brush and Replacement Tips— recommended<br />

for cleaning the Contacts (If fiberglass brushes are not allowed<br />

on the test floor, although not optimum, nylon brushes<br />

can be substituted.)<br />

EXTRAS:<br />

Finger Cots— recommended to prevent contaminating Contactor<br />

components with skin oils<br />

Protective Eye wear— recommended to protect technicians<br />

from Test Floor/Contactor components, Compressed Air and<br />

<strong>Johnstech</strong>’s <strong>Maintenance</strong> & <strong>Inspection</strong> Kit<br />

www.johnstech.com<br />

©2010 <strong>Johnstech</strong> International Corporation<br />

All rights reserved.<br />

8<br />

<strong>Johnstech</strong>’s <strong>Maintenance</strong> & <strong>Inspection</strong> Kit contains many of<br />

the tools needed for maintenance and inspection and are designed<br />

especially for <strong>Johnstech</strong> high performance Contactors.<br />

Contact your <strong>Johnstech</strong> representative for more information.<br />

<strong>Maintenance</strong> Kit Part Numbers—<br />

with torque screwdriver: 706449<br />

without torque screwdriver: 706448


Cleaning & <strong>Maintenance</strong> Frequency<br />

Determining Frequency<br />

Due to a wide range of variables (like those listed below),<br />

each Test Floor must determine their optimal cleaning and<br />

maintenance intervals through effective use of statistical<br />

process control. By carefully monitoring and recording yield<br />

rates and following good test floor troubleshooting procedures,<br />

you will be able to clearly differentiate between interface<br />

vs. maintenance problems and an effective maintenance<br />

cleaning cycle can be established to match the needs of each<br />

Test Floor. Contact your <strong>Johnstech</strong> representative or Field<br />

Service for further information or help.<br />

Pad ROL200<br />

Series<br />

Handler Design and Setup<br />

Handlers have a variety of test plane configurations, device<br />

transportation methods, plunge mechanisms and accessories.<br />

Each Handler has its own unique attributes. Handler set-ups<br />

that are not optimized can increase the required maintenance<br />

frequency by contributing to premature Contactor and Elastomer<br />

wear and Oxide Build-up on the Contacts. By working<br />

with <strong>Johnstech</strong> and your Handler supplier, you can optimize<br />

Handler performance to minimize downtime.<br />

Correct Contact Compressed Height<br />

Incorrect contact compressed height reduces the effectiveness<br />

of the Contact’s self-cleaning wipe and may cause increased<br />

oxide build-up and/or decreased contact life and load board<br />

pad life. It may also adversely affect Elastomer life by creating<br />

tears, cuts or Compression Set (permanent deformation). See<br />

examples on Page 13. The contact compressed height for each<br />

Contactor is specified on the Design Data Sheet><br />

Package and Device Plating Variations<br />

Variations in packages can affect your maintenance schedule.<br />

Different package vendors, or even different device lots, may<br />

have varying amounts of Mold Flash that can increase wear on<br />

the Contactor and alter device placement. Also, the method<br />

used for plating the device can vary the rate of debris buildup,<br />

therefore varying the maintenance interval.<br />

Contaminants<br />

Accumulation of contaminants (such as Oxides and Mold Flash)<br />

will contribute to continuity failures during the test process.<br />

General Test Floor <strong>Maintenance</strong> Activities<br />

The frequency of Handler maintenance procedures also affects<br />

Contactor cleaning. For example, how often the Handler and<br />

handler test areas are blown free of debris impacts the effectiveness<br />

of the Contactor. Contactors exposed to increased<br />

levels of foreign debris are likely to require more frequent<br />

maintenance and cleaning.<br />

9<br />

www.johnstech.com<br />

©2010 <strong>Johnstech</strong> International Corporation<br />

All rights reserved.


Pad ROL200<br />

Series<br />

If experiencing problems<br />

in automated<br />

test, first answer these<br />

2 questions.<br />

1) Does the test socket<br />

work when manually<br />

testing with the<br />

Manual Actuator<br />

2) Do the Witness<br />

Marks from the Manual<br />

Actuator test look the<br />

same as those from the<br />

automated test<br />

If the answer to both<br />

questions is YES, then<br />

your test problem is<br />

probably caused by<br />

some variable other<br />

than your <strong>Johnstech</strong><br />

Contactor.<br />

If the answer to either<br />

question is NO, then<br />

read through the checklists<br />

on these 2 pages,<br />

under the problem (in<br />

red) that you are experiencing.<br />

If this application has<br />

run well previously<br />

but is now failing,<br />

the troubleshooting<br />

must determine what<br />

has changed. If this<br />

is a new application<br />

troubleshooting must<br />

examine the original<br />

design.<br />

Pre-<strong>Maintenance</strong> Troubleshooting<br />

This Pre-<strong>Maintenance</strong> Troubleshooting section is to<br />

help you determine which part of your <strong>Johnstech</strong><br />

Contactor may be inspected and/or serviced to address<br />

a particular Test problem. This section doesn’t<br />

cover Test Floor, Handler, Device or any other variables<br />

that may be contributing to your Test problem.<br />

If you still experience problems after following<br />

the <strong>Maintenance</strong> Instructions herein, contact<br />

your local <strong>Johnstech</strong> Representative or fill-out our<br />

online Tech Help Form at www.johnstechhelp.com.<br />

Experiencing Yield Fall-Off<br />

There are many reasons you may be experiencing Yield Fall-<br />

Off but it can frequently be attributed to either Parametric<br />

or Continuity Failures.<br />

Parametric Failures are typically due to increased Contact<br />

Resistance which can be caused by:<br />

· Dirty Contacts<br />

Inspect Contacts per instructions on Page 13.<br />

· Worn or Damaged Elastomers<br />

Inspect Elastomers per instructions on Page 13.<br />

· Device-Pad-to-Contact Alignment<br />

Inspect the Contactor Registration per instructions on Page 12.<br />

· Worn or Damaged Alignment Plate<br />

Inspect the Alignment Plate under Contactor <strong>Inspection</strong><br />

instructions on Page 12.<br />

· Worn or Damaged Leadbacker/Nest<br />

Inspect the Leadbacker and Nest.<br />

· Oxidation/Contamination of the Load Board<br />

Inspect the Load Board per instructions on Page 12.<br />

· Excessive Load Board Pad Wear<br />

Inspect the Load Board per instructions on Page 12.<br />

Continuity Failures are typically due to Open/Short Failures<br />

which can be caused by:<br />

· Excessive Loose Debris<br />

Inspect Contactor per instructions on Page 12.<br />

· Worn or Damaged Contacts<br />

Inspect Contacts per instructions on Page 13.<br />

· Worn or Damaged Elastomers<br />

Inspect Elastomers per instructions on Page 13.<br />

· Worn or Damaged Alignment Plate<br />

Inspect the Alignment Plate under Contactor <strong>Inspection</strong><br />

instructions on Page 12.<br />

· Worn or Damaged Leadbacker/Nest<br />

Inspect the Leadbacker and Nest.<br />

· Contamination of the Load Board<br />

Inspect the Load Board per instructions on Page 12.<br />

www.johnstech.com<br />

©2010 <strong>Johnstech</strong> International Corporation<br />

All rights reserved.<br />

10


Pre-<strong>Maintenance</strong> Troubleshooting<br />

Experiencing Device Damage or Jamming<br />

There can be many reasons why you experience Device<br />

Damage or Jamming. For example, incorrectly designed or<br />

incompatible, worn or damaged Handler/Contactor components<br />

may cause Pad Damage or Device Jamming.<br />

Device Pad Damage or Improper Wipe can happen when<br />

Contacts are out of alignment. Witness Marks will be offcenter<br />

on the device pads, which can occur due to:<br />

· Worn or Damaged Alignment Plate Opening<br />

Inspect the Alignment Plate under Contactor <strong>Inspection</strong> instructions<br />

on Page 12.<br />

· Worn or Damaged Leadbacker/Nest<br />

Inspect the Leadbacker and Nest.<br />

· Changes in Package Singulation<br />

Verify that the Alignment Plate and Leadbacker are correct for the<br />

Device by comparing device dimensions to the Design Data Sheet<br />

(see Page 7).<br />

· Improper Overtravel Control<br />

Verify that Leadbacker/Nest has proper Overtravel control. Refer<br />

to the Contactor Specifications on your Design Data Sheet for<br />

Compressed, Uncompressed and Overtravel Stop measurements.<br />

· Worn or Damaged Housing Slots<br />

Inspect Housing per instructions on Page 13.<br />

Pad ROL200<br />

Series<br />

Device Pad Damage or Improper Wipe can also occur when<br />

devices experience over deflection, whereby large Witness<br />

Marks appear. This can be attributed to:<br />

· Worn or Damaged Contacts<br />

Inspect Contacts per instructions on Page 13.<br />

· Worn or Damaged Elastomers<br />

Inspect Elastomers per instructions on Page 13.<br />

· Improper Elastomers or Elastomer Installation<br />

Verify that Elastomers are correct per your Design Data Sheet and<br />

make sure Installation was performed per instructions on Page 20.<br />

· Worn or Damaged Leadbacker/Nest<br />

Inspect the Leadbacker and Nest.<br />

· Improper Overtravel Control<br />

Verify that Leadbacker/Nest has proper Overtravel control. Refer<br />

to the Contactor Specifications on your Design Data Sheet for<br />

Compressed, Uncompressed and Overtravel Stop measurements.<br />

· Worn or Damaged Housing Tail Stop<br />

Inspect the Contactor per instructions on Page 12.<br />

Device Jams can occur due to:<br />

· Device-Pad-to-Contact Alignment<br />

Inspect the Contactor Registration per instructions on Page 12.<br />

· Worn or Damaged Alignment Plate Opening<br />

Inspect the Alignment Plate opening under Contactor <strong>Inspection</strong><br />

instructions on Page 12.<br />

· Worn or Damaged Leadbacker/Nest<br />

Inspect the Leadbacker and Nest.<br />

· Changes in Package Singulation<br />

Verify that the Alignment Plate and Leadbacker are correct for the<br />

Device by comparing device dimensions to the Design Data Sheet.<br />

· Improper Overtravel Control<br />

Verify that Leadbacker/Nest has proper overtravel control. Refer<br />

to the Contactor Specifications on your Design Data Sheet for Compressed,<br />

Uncompressed and Overtravel Stop measurements.<br />

11<br />

www.johnstech.com<br />

©2010 <strong>Johnstech</strong> International Corporation<br />

All rights reserved.


Pad ROL200<br />

Series<br />

Figure 1: Example of a Load<br />

Board Pad Pattern<br />

Load Board & Contactor <strong>Inspection</strong><br />

Load Board <strong>Inspection</strong><br />

<strong>Johnstech</strong> recommends performing a thorough inspection of<br />

the Load Board before initial installation of the Contactor, as<br />

well as when performing routine maintenance. First, however,<br />

verify your Load Board against the Load Board Drawing that<br />

was sent to you either with your Quote or Order.<br />

Next, check the Contact Land Pad Pattern for signs of wear<br />

on the Gold. See Figure 1. If Nickel is showing, make sure<br />

that it is not excessive. It is acceptable to utilize the Nickel<br />

surface during testing; however, in some RF applications,<br />

signal degradation will occur. Load Boards with wear that<br />

extends deeper than the Nickel surface, through to the Copper,<br />

can cause damage to the Contacts and Elastomers and should<br />

be replaced or repaired.<br />

NOTE: Excessive Load Board wear is typically caused by<br />

Contact deflection or excessive force on the socket Housing.<br />

Figure 2: Example of worn (vs.<br />

not worn on right) Alignment<br />

Plate Wall; needs to be replaced<br />

Contactor <strong>Inspection</strong><br />

CAUTION: Use special care during the inspection process.<br />

Excessive force can fracture the Housing Slots.<br />

Figure 3: Example of backlit<br />

Alignment Plate Wear Test<br />

Figure 4: Examples of Tail<br />

Stop Wall Wear<br />

Before removing Contactor from the Load Board, use a minimum<br />

of 10X magnification to inspect it for:<br />

· Damaged, missing or excessively worn Contacts<br />

· Debris and Mold Flash trapped around Contacts<br />

· Cracks or chipping in the Housing or Alignment Plate<br />

· Cracked, deformed or missing Contact Slot Walls<br />

· Worn Alignment Plate (ALPL) Walls — see Figure 2.<br />

Complete ALPL analysis is a more complex topic than can be<br />

fully addressed here, but the following quick check-up may be<br />

helpful.<br />

NOTE: Remove Contactor from Load Board (per instructions<br />

on Pages 14) to test for Alignment Plate (ALPL)<br />

Wear. On a backlit surface, place device into the ALPL<br />

opening and then push it to one corner (see Figure 3).<br />

Use a Feeler Gauge Stock of 0.1mm, to check the gaps on<br />

the opposite sides. If Feeler Gauge Stock slips in and out<br />

of gap easily, the ALPL may need to be replaced.<br />

· Worn handler Alignment Pin Holes (contact your <strong>Johnstech</strong><br />

representative for Bushings to reduce Contactor wear.)<br />

If any of the above conditions are observed, Contactor <strong>Maintenance</strong><br />

and possibly Contact/Elastomer or ALPL replacement<br />

is required.<br />

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©2010 <strong>Johnstech</strong> International Corporation<br />

All rights reserved.<br />

12


Housing, Elastomer & Contact <strong>Inspection</strong><br />

Housing <strong>Inspection</strong><br />

In order to inspect the Housing, Elastomers and<br />

Contacts, the Contactor must be removed from Load<br />

Board and disassembled. Refer to instructions on<br />

Pages 14-15.<br />

Pad ROL200 Series Housings have a recommended lifespan<br />

of 2 million insertions. Take the dismounted/disassembled<br />

Contactor and using a minimum of 10X magnification, inspect<br />

the Housing for signs Tail Stop wear. If the Tail Stop depth<br />

exceeds 0.05mm (see Figure 4), replace Housing. Conversely,<br />

if the Contact Wipe on the Device Pad is not placed correctly<br />

(see Figure 5), check the Alignment Plate and Tail Stop Wall<br />

for wear. If observed, replace the Alignment Plate.<br />

Elastomer <strong>Inspection</strong><br />

Using 10X+ magnification, inspect Elastomers for signs of:<br />

· Cuts or tears · Compression Set<br />

· Stretched sections<br />

Pad ROL200 Series Elastomers should last to 300,000 insertions,<br />

but there are many factors that affect Elastomer life.<br />

Upon inspection, if you see excessively cut or torn Elastomers<br />

(see Figure 6), or if the Compression Set exceeds 0.05mm (see<br />

Figure 7), replace Elastomers to regain optimum performance.<br />

Contact <strong>Inspection</strong><br />

Using 10X+ magnification, inspect Contacts for signs of:<br />

· Worn Tips (See Figure 8) · Scratches or Markings<br />

· Oxide Buildup (See Figure 9) · Debris Buildup<br />

· Compressed/Distorted Shape<br />

Pad ROL200 Series Contact life depends on a number of variables.<br />

Refer to page 4. If any of the conditions listed above<br />

are observed, discard used Contacts and replace with new<br />

ones. Also, for optimum performance, if you know the Contacts<br />

have run their recommended lifespan, or you can see that wear<br />

exceeds 0.10mm, replace with new Contacts.<br />

Pad ROL200<br />

Series<br />

Figure 5: Acceptable Contact<br />

Wipe on Pad (Matte Tin)<br />

Figure 6: Example of Cut<br />

Elastomer; replace.<br />

Figure 7: Example of Compression<br />

Set; replace.<br />

Figure 8: New Low-Force XL<br />

Contact (left) vs. worn Low-<br />

Force XL Contact (right) tested<br />

on NiPdAu device<br />

Oxide Buildup<br />

The self-cleaning wipe-action of ROL technology is designed<br />

to greatly reduce the amount of Oxide Buildup on Contacts.<br />

However, some Oxide Buildup will occur if Contactors are<br />

unused for 2 or more days, appearing dull gray in color (see<br />

Figure 9). A light brushing or a few device insertions will<br />

typically remove the Oxide barrier and expose a shiny surface.<br />

Clean the Contactor after prolonged downtime or if you experience<br />

a decrease in yields. Refer to Cleaning Procedures on<br />

Pages 16-17.<br />

NOTE: If Contacts have significant/excessive Oxide Build-up,<br />

check all components in Test Cell to ensure that device alignment<br />

and plunge depth are correct.<br />

13<br />

Figure 9: Example of Oxide<br />

Buildup on Contact Tip (photo<br />

is from a test on Matte Tin).<br />

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All rights reserved.


Pad ROL200<br />

Series<br />

Figure 10: Screw Tightening<br />

Pattern<br />

Contactor Removal and Installation<br />

Contactor Removal & Installation Instructions<br />

It is recommended that you remove your Pad<br />

ROL200 Series Contactor from the Load Board<br />

before performing any component inspection,<br />

cleaning and/or maintenance.<br />

Step 1— Remove Contactor<br />

Start removal of the Contactor from the Load Board by loosening<br />

the fasteners. Use a microscope, to watch for Contacts<br />

or Ground Insert sticking to the mounting surface while carefully<br />

lifting Contactor from Load Board. If either is sticking,<br />

apply several drops of Isopropyl Alcohol through Contact Slots<br />

and allow it to soak for 2 minutes. Once free, inspect it for<br />

any loose or missing Contacts. Mount the Contactor to the<br />

Acrylic Shipping Plate (shown on Page 5).<br />

Step 2— Perform <strong>Maintenance</strong> & Cleaning<br />

Perform the maintenance and cleaning per the instructions<br />

contained on the following pages.<br />

Step 3— Clean Load Board<br />

Before remounting the Contactor to the Load Board, ensure<br />

that no debris is present in the interface area. If necessary,<br />

use compressed air and/or Isopropyl Alcohol with a clean<br />

lint-free cloth to carefully wipe the bottom of the Contactor<br />

and the surface of the Load Board clean.<br />

NOTE: NEVER use Acetone or other solvents.<br />

Recommended<br />

Torque Values<br />

in.-lb. Nm<br />

0-80 1.0 0.11<br />

2-56 2.0 0.23<br />

4-40 5.0 0.56<br />

M1.4 x 0.3 0.4 0.04<br />

M1.6 x 0.35 0.6 0.06<br />

M2 x 0.40 1.3 0.15<br />

M2.5 x 0.45 2.5 0.28<br />

M3 x 0.5 4.5 0.51<br />

M4 x 0.7 8.0 0.90<br />

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All rights reserved.<br />

14<br />

Step 4— Install Contactor<br />

Refer to the Load Board Drawing that was sent with either<br />

your Quote or Order for proper footprint layout. Fasten the<br />

Contactor to the Load Board by fitting the screws through the<br />

Contactor Assembly and engaging several threads. Under a<br />

microscope or 10X Eye Loupe, inspect the Contact tips for<br />

alignment. Misaligned Contacts can damage the Alignment<br />

Plate, Housing and Load Board. Use the Elastomer Tool to realign<br />

the Contacts where necessary. Evenly tighten the fasteners<br />

in a crisscross pattern. See Figure 10. To avoid damage<br />

to the Contactor or threaded inserts in the Load Board, the<br />

Contactor Mounting Screws should be tightened, according to<br />

the Recommended Torque Values in the table at left.<br />

Step 5— Verify Contacts<br />

Verify that all Contacts are properly positioned.<br />

Gently actuate all of the Contacts with an Elastomer Tool to<br />

ensure proper Contact motion.<br />

Step 6— Verify Test Set-up<br />

Verify the Device-to-Contactor alignment and Handler plunge<br />

depth, as well as the X-Y presentation.


Contact & Elastomer Removal<br />

Contact & Elastomer Removal Instructions<br />

Pad ROL200<br />

Series<br />

CAUTION: Avoid putting pressure on Slot Walls and Webs<br />

by not resting hands or tools in these areas while working<br />

on the Contactor. See Figures 11 & 12.<br />

Step 1— Remove Inner/Front Elastomer<br />

A. Turn Contactor over so Load Board side faces up.<br />

B. Use a Tweezers to pull out the Inner or Front (gray)<br />

Elastomer from all four sides of the Contactor. See<br />

Figure 13.<br />

C. Inspect Elastomer per instructions on Page 13 to determine<br />

whether Elastomers can be reused or need to be<br />

discarded.<br />

Step 2— Remove Contacts<br />

A. With Contactor still Load Board side up, use a Tweezers<br />

to carefully pull Contacts out of Housing. See Figure 14.<br />

(Many people find it easier to start at one corner and<br />

work your way around the Contactor, but removal order is<br />

unimportant.)<br />

B. Inspect Contacts to determine if they need to be discarded<br />

or can be reused. Refer to Page 13 for help.<br />

C. If your intent is just to change out the Elastomers and<br />

reuse the Contacts, take extra care in the removal process.<br />

Do not squeeze or bend them and do not touch the<br />

Tips. Damaged Tips can affect performance.<br />

D. Either discard worn Contacts or set aside for reassembly.<br />

Step 3— Remove Outer/Back Elastomer<br />

Like in Step 1 above, use a Tweezers to pull out the Outer<br />

or Back (yellow) Elastomer. See Figure 15. Inspect for<br />

signs of wear per instructions on Page 13 and either set<br />

aside for reinstallation or discard.<br />

NOTE: It is recommended to just discard used Elastomers<br />

and assemble Contactor with new ones, but if they are in<br />

exceptionally good shape, they can be set aside and reinstalled.<br />

Blow with Compressed Air before reinstalling.<br />

Figure 11:<br />

Figure 12:<br />

→<br />

Slot Walls<br />

Slot Webbing<br />

Figure 13: Removal of Inner/<br />

Front Elastomer<br />

→<br />

Figure 14: Contact Removal<br />

→<br />

Figure 15: Removal of Outer/<br />

Back Elastomer<br />

15<br />

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©2010 <strong>Johnstech</strong> International Corporation<br />

All rights reserved.


Pad ROL200<br />

Series<br />

Figure 16: Separating Housing<br />

and Alignment Plate<br />

→<br />

Contactor Cleaning<br />

If debris buildup is observable when inspecting<br />

the Contactor, or you experience a drop in Yields<br />

or an increase in Resistance, follow the Light<br />

Cleaning Procedure given here.<br />

NOTE: A Fiberglass brush is always recommend for Contactor<br />

cleaning but if you don’t have or are not allowed to use a<br />

fiberglass brush, a nylon brush may be used a substitute.<br />

Light Cleaning Procedure<br />

Step 1— Remove Contactor from Load Board<br />

Refer to instructions on Page 14, Step 1.<br />

Step 2— Remove the Alignment Plate<br />

Use a Scalpel to gently pry apart the Housing and Alignment<br />

Plate, working in an even and incremental manner around<br />

the Housing to avoid binding. See Figure 16.<br />

Figure 17: Correct direction<br />

for Contact brushing on the<br />

Top Side of the Contactor<br />

Figure 18: Correct direction<br />

for Contact brushing on the<br />

Bottom Side of the Contactor<br />

Figure 19: Compressed<br />

Air Cleaning<br />

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→<br />

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All rights reserved.<br />

16<br />

Step 3— Brush the Top Side of Contactor<br />

A. Mount Contactor to the Acrylic Mounting Plate.<br />

B. Use a fiberglass (or nylon) brush to gently clean both<br />

the Perimeter and Ground (even if in a Ground Insert)<br />

Contact Tips, brushing from the outside in, toward the<br />

center of the Contactor. See Figure 17.<br />

Step 4— Brush the Bottom Side of Contactor<br />

A. Remove Contactor from the Acrylic Mounting Plate and<br />

turn over so the Load Board side is up.<br />

B. Use the fiberglass (or nylon) brush again to gently clean<br />

both the Perimeter and Ground (even if in a Ground Insert)<br />

Contact Bottoms. This time brush from the center<br />

of the Contactor outward. See Figure 18. Avoid brushing<br />

Elastomers.<br />

Step 5— Clear the Debris<br />

Remove any remaining loose debris from the Contactor using<br />

one or both of these methods:<br />

· Dry, clean Compressed Air (20psi or less). See Figure 19.<br />

· A small vacuum<br />

Be sure to thoroughly cover every part of the Contactor, including<br />

the Elastomer and Contact Slots. If no loose debris<br />

remains, the Contactor may be reassembled and reinstalled.<br />

NOTE: If remaining debris or foreign matter is observed,<br />

even after performing this Light Cleaning Procedure, try<br />

the Thorough Cleaning Procedure with an Ultrasonic<br />

Cleaner per the instructions on the facing page.<br />

Step 6— Clean the Handler<br />

Clean the Handler per the manufacturer’s recommendations.<br />

Step 7— Reinstall the Contactor<br />

If no loose debris remains on the Contactor, remount it to<br />

the Load Board per the instructions on Page 14, Step 4.


Contactor Cleaning<br />

Thorough Cleaning Procedure<br />

If the Contactor and Alignment Plate have excessive<br />

debris buildup, it is strongly recommended<br />

to perform a thorough cleaning with an Ultrasonic<br />

Cleaner. Only execute this procedure in a<br />

well ventilated area with an Exhaust Hood.<br />

CAUTION: The Ultrasonic Cleaner should have a maximum<br />

power of 500W and a catch basket in the tank that prevents<br />

the Contactor from touching settled debris<br />

Step 1— Prepare the Housing<br />

A. Remove the Contactor from the Load Board per instructions<br />

on Page 14, Step 1.<br />

B. Gently pry apart the Housing and Alignment Plate per<br />

instructions in Step 2 on the opposite page.<br />

C. Remove Ground Insert if Contactor has one, Refer to<br />

ground insert remove instructions on page 27.<br />

D. If contacts and elastomers require replacement for<br />

either the housing or Ground Insert, removed the used<br />

contacts and elastomers<br />

E. If the contacts and elastomers are in good condition<br />

they can be left in the housing during the following<br />

cleaning procedures.<br />

Pad ROL200<br />

Series<br />

Figure 20: Example of Cleaning<br />

a Housing in an Ultrasonic<br />

Cleaner; note left position.<br />

Figure 21: Example of Rinsing<br />

a Housing in an Ultrasonic<br />

Cleaner; note right position.<br />

Step 2— Prepare the Bath<br />

Prepare a bath of diluted Isopropyl Alcohol (70/30 Alcohol/<br />

Water) OR a heated (40-50ºC max) mild acidic (7.1 > ph ><br />

3.0) solution.<br />

NOTE: If a Sonic Cleaner is unavailable, gently brush the<br />

Housing with bath solution (see above), rinse in Deionized<br />

Water and dry Housing out completely.<br />

Step 3— Perform the Cleaning<br />

Operate Ultrasonic Cleaner per Manufacturer’s Instructions only.<br />

A. Fully immerse the populated or unpopulated housing<br />

device-side down. The bath should be pre-heated and<br />

run for a minimum of a 30 minute cycle. See Figure 22.<br />

B. Also, place the alignment plate and the Ground Insert<br />

into the bath.<br />

B. Remove Housing, alignment plate and Ground Insert<br />

from the bath and sonic rinse and rinse with deionized<br />

water for about 10 minutes. See Figure 23.<br />

NOTE: For populated Contactor Housings or Populated<br />

Ground Inserts, inspect for missing Contacts before<br />

moving then to the rinse bath. Some Contacts may<br />

dislodge during the ultrasonic cleaning. Collect them and<br />

move them to the rinse bath and then reinstall before<br />

drying.<br />

17<br />

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All rights reserved.


Pad ROL200<br />

Series<br />

Contactor Cleaning<br />

Step 4— Dry the Contactor<br />

Current leakage may occur during testing if moisture<br />

remains on the Contacts. To prevent this:<br />

A. Carefully pat the Contactor dry with a lint-free cloth.<br />

B. Blow the Contactor dry with heated air. See Figure 22.<br />

C. If necessary, place in oven for approx. 10 minutes.<br />

Figure 22: Heated Air Drying—<br />

a common Hair Dryer will suffice.<br />

CAUTION: DO NOT use heat guns to blow Contactors dry.<br />

Heated air should not exceed 100ºC or be utilized for<br />

longer than 30 minutes.<br />

Step 5— Reassemble the Contactor<br />

Reassemble the Contactor per instructions on Pages 18-19.<br />

Step 6— Reinstall Contactor<br />

A. Inspect Contactor one final time for any debris, damage<br />

or moisture.<br />

B. Remount Contactor to Load Board per instructions on<br />

Page 14, Step 4.<br />

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All rights reserved.<br />

18


Elastomer Installation<br />

Elastomer Installation Instructions<br />

Before beginning, use low-pressure, clean Compressed<br />

Air on Contactor to blow away any debris.<br />

The yellow/gray Elastomers mentioned below refer to the matte<br />

tin configuration. (The NiPdAu package configuration uses the<br />

blue/red Elastomer. See Page 4.)<br />

Step 1— Cut Elastomers to Length<br />

A. Turn Contactor Load Board side up.<br />

B. Lay a length of the yellow Elastomer next to the Outer<br />

or Back Elastomer Slot. (Red Elastomer for the NiPdAu<br />

configuration)<br />

C. Use a blade to mark the Elastomer at the correct length<br />

(see Figure 23), which is just a little short of the End<br />

Well (see Figure 24). Use care to not cut the Housing.<br />

D. Use a micro-scissors to cut Elastomer straight across.<br />

E. Cut remaining 3 lengths of the Outer/Back (yellow)<br />

Elastomers to this same size.<br />

F. Proceed on to cut the 4 Inner/Front Elastomers (gray for<br />

Gold-Plated Contacts; blue for Low-Force XL Contacts) to<br />

this same length.<br />

G. Store unused Elastomer in original packaging only.<br />

Step 2— Install Outer/Back Elastomers<br />

A. Place a purple Elastomer over the Outer/Back Elastomer Slot.<br />

B. Using an Elastomer Tool, gently push Elastomer into Slot.<br />

See Figure 25. Elastomer should extend just slightly less<br />

than the end of the End Wells.<br />

C. Continue installing remaining (purple) Outer Elastomers.<br />

Step 3— Install Inner/Front Elastomers<br />

A. Place gray Elastomer over the Inner or Front Elastomer<br />

Slot. (Blue Elastomer for the NiPdAu configuration)<br />

B. Position a Tweezers over the Contact Rib in the middle of<br />

the Elastomer Slot, then gently squeeze the Elastomer and<br />

tuck it into the Elastomer Slot. See Figure 26. Continue<br />

working towards the right, “pinching and tucking” at each<br />

rib in sequence. See Figure 27. Use a delicate touch when<br />

squeezing Elastomer to avoid nicks and cuts.<br />

C. Once the right side is completed, go back to the center<br />

and work toward the left. Finish by pushing Elastomer<br />

Ends into End Wells. Check to make sure Elastomer just<br />

barely extends into the End Wells (see Figure 24). If<br />

the Elastomer appears off-center, please pull it out and<br />

reinstall. Optimum performance is achieved when Elastomers<br />

are centered in the Elastomer Slot.<br />

NOTE: Lubricate Elastomers with Isopropyl Alcohol, if<br />

needed, to facilitate installation. Please use special<br />

care to avoid bunching, stretching or twisting the<br />

Elastomer. Proper Elastomer installation helps optimize<br />

performance.<br />

D. Continue installing the remaining Inner Elastomers.<br />

Please note that they will fit more snugly into the Inner<br />

Elastomer Slots than how it was for the Outer Elastomers.<br />

19<br />

Pad ROL200<br />

Series<br />

Figure 23: Mark Elastomer at<br />

appropriate length<br />

Figure 24: Proper fit of Elastomers<br />

into End Wells<br />

Figure 25: Use Elastomer Tool<br />

to push Elastomer into Outer Slot<br />

→<br />

→<br />

→<br />

Figure 26: Use Tweezers to<br />

gently “pinch and tuck” Elastomer<br />

into Inner Elastomer Slot<br />

Figure 27: Work from Center<br />

to Right and then Center to Left<br />

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Pad ROL200<br />

Series<br />

→<br />

Contact Installation<br />

Contact Installation Instructions<br />

CAUTION: Avoid putting pressure on Slot Walls and Webs<br />

by not resting hands or tools in these areas while working<br />

on the Contactor. See Figures 11 & 12 on Page 15.<br />

Figure 28: Align above and<br />

between Elastomers<br />

→<br />

Step 1— Align and Insert Contact<br />

A. Turn Contactor Load Board side up.<br />

B. Using a Tweezers, dip Contact in Isopropyl Alcohol. (The<br />

alcohol lubricates the Contact, making insertion easier.)<br />

C. Start installation at the far left Contact Slot on any side.<br />

Align the Contact above the Contact Slot (see Figure 28)<br />

and press the Contact down between the gap in the Elastomers<br />

(see Figure 29).<br />

Step 2— Position Contact and Insert Further<br />

Manuever the head of the Contact down and towards the<br />

center of the Contactor. See Figure 30.<br />

Figure 29: Insert downward<br />

into gap between Elastomers<br />

→<br />

Step 3— Final Adjustment<br />

Use Tweezers to gently rotate the Contact Tail down onto the<br />

Outer (purple) Elastomer until the fit is snug. See Figure 31.<br />

Step 4— Installation Pattern<br />

Continue installing Contacts in the repeating left-right-center<br />

sequence shown below, per the steps above, until entire side<br />

is populated. Proceed on to each side in the same manner.<br />

Figure 30: Gently push<br />

Contact head towards center of<br />

Contactor<br />

→<br />

1 8 10 4 12 6 14 3 7 13 5 11 9 2<br />

Contact Insertion Order<br />

NOTE: It is recommended to mount the Contactor onto the<br />

Acrylic Mounting Plate (shown on Page 5) when not in use or<br />

for inspecting, storing or shipping. If the Contactor is stored<br />

on Acrylic Mounting Plate for over a week, loosen screws to<br />

avoid Compression Set on the Rear Elastomer.<br />

Figure 31: Gently push<br />

Contact tail down onto purple<br />

Elastomer<br />

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All rights reserved.<br />

20


Installation Verification<br />

In order to ensure optimum performance from your<br />

Pad ROL200 Series Contactor, it is very important<br />

to check and make sure that the Contacts and Elastomers<br />

are properly installed.<br />

Pad ROL200<br />

Series<br />

Turn your Contactor Load Board side up and compare<br />

to this picture of a properly populated Pad<br />

ROL200 Contactor:<br />

RTH Ground Configuration<br />

Shown<br />

Former configuration pictured here.<br />

Purple elastomer has been replaced by<br />

Yellow elastomer in current configuration.<br />

Correct/Proper Installation of Contacts/Elastomers<br />

Check to see that Elastomers are at least halfway<br />

into the End Wells and that they are not stretched,<br />

bunched or twisted. This photo is a close-up of the<br />

corner for a tighter view of the desired Elastomer/<br />

End Well relationship.<br />

Former configuration pictured here.<br />

Purple elastomer has been replaced by<br />

Yellow elastomer in current configuration.<br />

Close-up of Corner, displaying proper Elastomer lengths.<br />

If your installation does NOT look like these photos,<br />

please carefully disassemble the Contactor and<br />

rebuild it again per the directions on Pages 18-19.<br />

NOTE: A movie showing the Elastomer & Contact Installation<br />

Process is available for viewing and downloading at our<br />

website, www.johnstech.com, in the Pad ROL200 Product<br />

section.<br />

21<br />

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All rights reserved.


Pad ROL200<br />

Series<br />

Figure 32: RCI Ground Insert<br />

(New Elastomer retention<br />

design)<br />

Grounding Solutions<br />

The Pad ROL200 Series offers four main<br />

Grounding Options:<br />

1] “RCI” — ROL Contacts in a Copper Insert, for<br />

5x5-12x12 packages<br />

· New Elastomer retention design - (See Figure 32)<br />

· Original Snap Fit design - (See Figure 33)<br />

2] “CI” — a Copper Insert for 3x3 packages (See<br />

Figure 34);<br />

3] “EI” — Eco-1 Insert for 3x3 & 4x4 packages<br />

(See Figure 35)<br />

(See the EI Insert Owners Manual, Lit 1413A)<br />

4] “RTH” — ROL Contacts in Torlon Housing, for<br />

4x4-12x12 packages (refer to page 21)<br />

In order to maintain proper operation and ensure<br />

a long life for your Grounding Solution, you will<br />

need to perform cleaning and maintenance, much<br />

like you need to do for the other Components of<br />

your Pad ROL200 Series Contactor.<br />

Figure 33: RCI Ground Insert<br />

(Original Snap Fit design)<br />

Figure 34: CI Ground Insert<br />

Ground Inserts<br />

RCI, CI and EI ground inserts need to be removed for cleaning<br />

and maintenance per the instructions on Page 23. Then follow<br />

the Cleaning & Installation instructions on Page 23.<br />

Ground Contact <strong>Maintenance</strong><br />

<strong>Inspection</strong>, cleaning and change-out of the Ground Contacts<br />

& Elastomers can be performed in the same manner as the<br />

Perimeter Contacts and Elastomers. (However, please note that<br />

depending on which way the ground Contacts are oriented, the<br />

direction of brushing when performing the Light Cleaning Procedure<br />

will vary. Refer to Figures 15 & 18 on Page 16 for visual<br />

cues.)<br />

Figure 35: EI Ground Insert<br />

Former configuration pictured in<br />

Figure 32 and Figure 35. Purple<br />

elastomer has been replaced<br />

by Yellow elastomer in current<br />

configuration.<br />

22


Ground Insert <strong>Maintenance</strong><br />

Ground Insert Removal Instructions<br />

IMPORTANT: Use finger cots when handling Ground<br />

Inserts to avoid contamination with skin oils, which<br />

can degrade performance.<br />

Pad ROL200<br />

Series<br />

→<br />

Using covered fingers and/or the Elastomer Tool, press down<br />

on the Ground Insert. The Insert will easily release out of the<br />

Housing. See Figure 36 at right.<br />

Ground Insert Cleaning Instructions<br />

Step 1— Remove Contacts & Elastomers<br />

Once the Ground Insert is removed from the Housing, follow<br />

instructions for Contact and Elastomer removal on Page 15.<br />

Figure 36: A light downward<br />

push will free Ground Insert<br />

from Housing<br />

Step 2— Clean Ground Insert<br />

A. Clean the unpopulated Ground Insert with a fiberglass<br />

(or nylon) brush per the instructions on Page 16.<br />

B. Follow up with Ultrasonic Cleaning, per instructions on<br />

Page 17.<br />

C. Inspect for mushrooming or bending. If observed, contact<br />

<strong>Johnstech</strong> Field Service or your Representative.<br />

Step 3— Re-assemble Ground Insert<br />

Follow the instructions for Elastomer & Contact installation<br />

on Pages 19 & 20.<br />

Step 4— Blow with Compressed Air<br />

To clear away any remaining debris, blow the Insert with<br />

Compressed Air before reinstalling Ground Insert. Inspect for<br />

remaining debris. If observed, repeat cleaning process again.<br />

(Refer to Pages 16-17.)<br />

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©2010 ©2009 <strong>Johnstech</strong> International Corporation<br />

All rights reserved.<br />

23


Pad ROL200<br />

Series<br />

Elastomer retention<br />

grooves<br />

Ledges<br />

Ground Insert Installation<br />

New Elastomer Retention Ground Insert Design<br />

IMPORTANT: Always ensure Ground Insert is clean<br />

before installing and inspect used inserts for damage<br />

or wear.<br />

Step 1— Locate and Position the Ground Insert<br />

Under magnification locate your Ground Insert and flip the<br />

insert right side up and lay on a flat surface.<br />

Figure 37: Position the housing<br />

over the RCI ground insert.<br />

Step 2— Installation of the Ground Insert<br />

With the housing right side up, place the housing over the<br />

insert to begin the installation. Locate the two grooves on the<br />

insert (one on either side) to help guide the housing over the<br />

insert and position the housing over the insert. See Figure 37.<br />

Line up the ledges from the top of the housing with the<br />

Elastomer grooves in the Ground Insert.<br />

NOTE: When the housing and insert are properly oriented, the<br />

housing will drop completely down flat onto the insert. The top<br />

of the insert will protrude slightly above the top surface of the<br />

housing. Do not force the insert and housing together. If the<br />

housing does not drop completely down onto the insert, the<br />

parts are not oriented properly.<br />

Figure 38: Insert the two blue<br />

retention elastomers. (cutaway<br />

view)<br />

Step 3— Install Blue Retention Elastomer<br />

Insert the two Blue Retention Elastomers (from the top side)<br />

along the sides of the insert. Cut the Blue Elastomers to the<br />

correct length, not exceeding the channel opening.<br />

See Figure 38 & 39. Use the probe tool shown on page 8.<br />

NOTE: Retention elastomers are installed on the sides of the<br />

insert.<br />

Figure 39: Insert the two blue<br />

retention elastomers. (top view)<br />

NOTE: Do not confuse the Blue Retention Elastomer with the<br />

Blue Low-Force XL front Elastomers used in the NiPdAu package<br />

configuration shown on page 4. The Blue Retention Elastomers are<br />

significantly smaller in diameter and exhibit a Blue translucent<br />

color.<br />

Figure 40: Proper installation of<br />

Elastomers, Contacts and Insert.<br />

(bottom view)<br />

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©2010 <strong>Johnstech</strong> International Corporation<br />

All rights reserved.<br />

24


Grounding Installation<br />

Original Snap Fit RCI Ground Insert<br />

Pad ROL200<br />

Series<br />

NOTE: If your Contactor uses the original Snap-fit RCI Ground<br />

Insert design, please follow these instructions.<br />

IMPORTANT: Always ensure Ground Insert is clean before<br />

installing and inspect used Inserts for damage or wear.<br />

Step 1— Locate Orientation Marks<br />

With Contactor Load Board side up, locate and align the<br />

orientation marks on the Ground Insert and Housing. See<br />

Figure 41.<br />

NOTE: Some especially small inserts may not have enough<br />

area available for Orientation Marks.<br />

Step 2— Install Ground Insert<br />

Gently press the Ground Insert downward into the Housing<br />

with uniform force on all sides and making sure the insert<br />

remains coplanar. The insert should easily press into place.<br />

See Figure 42.<br />

NOTE: The Copper Insert for 3x3 devices is a slip-fit.<br />

Figure 41: Orientation Marks<br />

→<br />

Figure 42: Press Ground<br />

Insert down to install<br />

25<br />

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©2010 <strong>Johnstech</strong> International Corporation<br />

All rights reserved.


All statements, technical<br />

information and recommendations<br />

related to the Seller’s products<br />

are based on information believed<br />

to be reliable, but the accuracy<br />

or completeness thereof is not<br />

guaranteed. Before utilizing the<br />

product, the user shall determine<br />

the suitability of the product<br />

for its intended use. The user<br />

assumes all risks and liability<br />

whatsoever in connection with<br />

such use. Any statements or<br />

recommendations of the Seller<br />

which are not contained in the<br />

Seller’s current publications shall<br />

have no force or effect unless<br />

contained in an agreement signed<br />

by an authorized officer of the<br />

Seller. The statements contained<br />

herein are made in lieu of all<br />

warranties expressed or implied,<br />

including but not limited to the<br />

implied merchantability and<br />

fitness for a particular purpose<br />

which warranties are hereby<br />

expressly disclaimed. Seller shall<br />

not be liable to the user or any<br />

other person under any legal<br />

theory, including but not limited<br />

to negligence or strict liability,<br />

for any injury or for any direct or<br />

consequential damages sustained<br />

or incurred by reason of the use<br />

of any of Seller’s products or<br />

services that were defective.<br />

Worldwide Headquarters<br />

1210 New Brighton Boulevard<br />

Minneapolis, MN 55413-1641 USA<br />

Tel: 612.378.2020<br />

Fax: 612.378.2030<br />

E-mail: info@johnstech.com<br />

www.johnstech.com<br />

Regional/Field Service Office — California, USA<br />

2450 Scott Boulevard<br />

Santa Clara, CA 95050-2504<br />

Tel: 408.448.2020<br />

Fax: 408.448.2030<br />

www.johnstechhelp.com<br />

Regional/Field Service Office — Singapore<br />

14 Robinson Road #13-00<br />

Far East Finance Building<br />

Singapore 048545<br />

Tel: 65.6385.2389<br />

Fax: 65.6323.1839<br />

I<br />

© Copyright 2009 <strong>Johnstech</strong> International<br />

Corporation Specifications subject to change.<br />

Specifications subject to change without notice.<br />

No part of this document may be reproduced<br />

in any form or by any means, electronic<br />

or mechanical, including photocopying,<br />

recording or by any information storage or<br />

retrieval system, without expressed written<br />

permission from <strong>Johnstech</strong>. <strong>Johnstech</strong> and<br />

<strong>Johnstech</strong> logo are registered trademark s<br />

in the USA and other countries. <strong>Johnstech</strong><br />

products and components are covered by<br />

patents and copyrights in the USA and other<br />

countries.<br />

For questions about anything contained in this<br />

<strong>Maintenance</strong> & <strong>Inspection</strong> Guide, contact your local<br />

<strong>Johnstech</strong> representative.<br />

If you are experiencing a technical problem or issue,<br />

fill out the online Tech Help Form at:<br />

www.johnstechhelp.com OR<br />

contact the nearest Field Service Office.<br />

China &<br />

EU RoHS<br />

Compliant<br />

LIT 1435E-211<br />

Printed in the USA on 100% Post-Consumer Recycled Paper made utilizing Wind Power.<br />

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